Six Sigma Based Quality Control Analysis for Wiring Harness Production at PT Tae Bong Indonesia
DOI:
https://doi.org/10.62007/joumi.v4i2.793Keywords:
Defect, DMAIC, DPMO, Quality Control, Six Sigma, Wiring HarnessAbstract
This study examines the quality performance of wiring harness production at PT Tae Bong Indonesia using the Six Sigma approach with the DMAIC methodology. The production process experiences a quality issue characterized by a defect rate of 6.15%, which exceeds the company’s maximum tolerance limit of 5%. The objective of this study is to evaluate process capability, identify dominant defect types, analyze root causes, and propose structured improvement strategies to reduce defects in the production process. This research uses a quantitative descriptive case study design based on production and defect data collected from January to June 2025. The analytical methods include Defects per Unit (DPU), Defects per Opportunity (DPO), Defects per Million Opportunities (DPMO), sigma level calculation, Pareto analysis, p-chart, fishbone diagram, and 5 Whys analysis. The results show an average DPMO value of 20,500 with a sigma level of 3.55, indicating that the process capability is at a moderate performance level. The dominant defects identified are burned wire, imperfect crimping, and retainer no locking, which contribute 78.64% of total defects. The root causes are mainly related to unstable machine parameters, inconsistent maintenance practices, non-standardized work methods, and weak inspection control. Proposed improvements focus on process parameter standardization, preventive maintenance enhancement, inspection system strengthening, and implementation of structured control plans. This study provides a practical reference for improving process stability and reducing defects in wiring harness manufacturing.
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